Hinged key retention system for product packaging

Abstract

A package for a product, a key retention system, and a retaining key may utilize one or both of a range limited hinge in the retaining key that enables the retaining key to span an opening in a container body and be supported at each of its ends when in a locked configuration to restrict removal of a product from the opening, and when in a released configuration in which one of the ends is released from the container body, flex about the hinge to allow for removal of the product from the opening, and a key latch that is movable between installation and operational configurations to selectively configure or more retaining ears to restrict movement of the retaining key. In some instances, multiple retaining keys may also engage one another across through cooperative latch members to span an opening in a container body.

Description

BACKGROUND

[0001] Conventionally, products have been packaged in a variety of ways, many of which present various limitations, including difficulty for an end user to insert the product within the package and / or to release the product without damage or loss to the contained products. An example of conventional packaging includes packaging molded or thermoformed into a rigid or semi-rigid plastic container for holding one or more products in one or more predetermined locations in the container. Another conventional type of packaging includes a flexible pouch into which product components may be inserted. In some instances, these packaging techniques may be combined. Containing products within a tray, pouch, or the like may also be supplemented by additional elements such as covers, straps, adhesive tape, or the like. The use of such additional elements, however, may not be desirable and may be cumbersome to the end user.

[0002] In particular, many packaging systems are subject to the competing desires of securely retaining and protecting products within packages during shipment and otherwise prior to use, and of enabling retained products to be quickly and easily removed from the packaging when needed. With some medical equipment, for example, it may be desirable to securely retain delicate and sterilized instruments used in medical procedures within a package for shipment and storage, yet enable those instruments to be removed as quickly and effortlessly as possible during the medical procedures.

[0003] Further, environmental concerns remain an important concern in the packaging industry, so it is also desirable to minimize waste associated with packaging systems both in connection with the manufacture of packaging and its disposal and / or recycling after use.

[0004] In addition, it has been found that, for example, with packaging systems using thermoformed container bodies, retaining heavier products in the container bodies can require relatively complicated constructions that increase packaging size and waste, and may require more effort to remove the packaged product.SUMMARY

[0005] The herein-described implementations address these and other problems associated with the art by providing in one aspect a package for a product, a key retention system, and a retaining key that utilize a range limited hinge in the retaining key that enables the retaining key to span an opening in a container body and be supported at each of its ends when in a locked configuration to restrict removal of a product from the opening, and when in a released configuration in which one of the ends is released from the container body, flex about the hinge to allow for removal of the product from the opening.

[0006] The herein-described implementations also address additional problems associated with the art by providing in another aspect a package for a product, a key retention system, and a retaining key that utilize a key latch that is movable between installation and operational configurations to selectively configure or more retaining ears to restrict movement of the retaining key beyond a locked configuration when the key latch is in the operational configuration.

[0007] The herein-described implementations also address additional problems associated with the art by providing in another aspect a package for a product, a key retention system, and a retaining key that utilize a pair of retaining keys including cooperative catch members that engage one another when the retaining keys are supported by key supports on opposite sides of a recess.

[0008] Therefore, consistent with one aspect of the invention, a package for a product may include a container body configured to support the product and including a recess through which the product may be removed from the container body, the container body further including first and second key supports disposed on opposite sides of the recess, and a retaining key supported by the container body and movable along an axis between locked and released configurations, the retaining key including first and second portions joined to one another by a range limited hinge for which relative rotation between the first and second portions is limited beyond a predetermined rotational relationship. When in the locked configuration, the first and second portions are respectively supported by the first and second key supports with the retaining key spanning the recess and with the range limited hinge restricting relative rotation between the first and second portions of the retaining key to retain a portion of the product in the recess, and when the retaining key is moved along the axis to the released configuration, the first portion of the retaining key is released from the first key support and is free to rotate relative to the second portion by the range limited hinge to allow for removal of the portion of the product retained by the retaining key from the recess.

[0009] In some embodiments, the second key support includes a channel having first and second ends, and the retaining key further includes a key latch coupled to the second portion of the retaining key and movable between installation and operational configurations, the key latch including a retaining ear configured to extend generally transverse to the axis of the retaining key and beyond a width of the channel when the key latch is in the operational configuration such that the retaining ear restricts movement of the retaining key through the channel beyond the locked configuration, and when the key latch is in the installation configuration, the retaining ear allows insertion of the second portion of the retaining key into the first end of the channel and out of the second end of the channel. Also, in some embodiments, the hinge is a living hinge that is integral with the first and second portions.

[0010] Further, in some embodiments, the retaining key further includes a retaining ear coupled to the second portion and extending generally transverse to the axis, the retaining ear configured to frictionally engage a first wall of the second key support within a channel of the second key support during at least a portion of the movement of the retaining key between the locked and released configurations. In some embodiments, the retaining key further includes a closed relief slot formed in the retaining key adjacent to the retaining ear and configured to enable flexure of the retaining ear during movement of the retaining key between the locked and released configurations.

[0011] In addition, in some embodiments, the first and second key supports are integrally-formed with the container body. In some embodiments, the container body and first and second key supports are formed of a thermoformed plastic. In addition, in some embodiments, the first key support includes a channel configured to receive the first portion of the retaining key when the retaining key is in the locked configuration to restrict relative rotation between the first and second portions of the retaining key. Moreover, in some embodiments, the retaining key is a first retaining key and the first key support includes a second retaining key configured engage the first portion of the first retaining key when the first retaining key is in the locked configuration to restrict relative rotation between the first and second portions of the retaining key. In some embodiments, the first key support includes a ledge and / or a receptacle configured to engage the first portion of the retaining key when the retaining key is in the locked configuration to restrict relative rotation between the first and second portions of the retaining key.

[0012] Consistent with another aspect of the invention, a retaining key for retaining a product in a recess of a container body of a type including first and second key supports disposed on opposite sides of the recess, may include first and second portions arranged along a first axis and respectively configured to be supported by the first and second key supports of the container body, each of the first and second portions including an outwardly-facing surface configured to face away from the recess of the container body and an inwardly-facing surface configured to face towards the recess of the container body, the outwardly-facing and inwardly-facing surfaces separated from one another along a second axis that is generally transverse to the first axis, a hinge joining the first and second portions and configured to provide relative rotation between the first and second portions about a third axis that is generally transverse to the first and second axes, and first and second opposing stop members respectively disposed on the first and second portions and configured to abut one another when the retaining key is in a locked configuration to restrict relative rotation between the first and second portions. The first and second opposing stop members may be separated from the hinge generally along the second axis with the hinge disposed closer to the outwardly-facing surfaces of the first and second portions than the first and second opposing stop members.

[0013] Consistent with another aspect of the invention, a retaining key for retaining a product in a recess of a container body of a type including first and second key supports disposed on opposite sides of the recess may include first and second portions respectively configured to be supported by the first and second key supports of the container body, each of the first and second portions including opposing first and second surfaces, the first surfaces of the first and second portions configured to face away from the recess of the container body when the first and second portions are supported by the first and second key supports of the container body, a hinge joining the first and second portions to one another proximate the first surfaces thereof to provide relative rotation between the first and second portions, and first and second opposing stop members respectively disposed on the first and second portions proximate the second surfaces thereof and configured to abut one another when the first and second portions are supported by the first and second key supports of the container body to limit relative rotation between the first and second portions when the first and second portions are supported by the first and second key supports of the container body and thereby restrict removal of the product from the container body.

[0014] Consistent with another aspect of the invention, a package for a product may include a container body configured to support the product and including a key support, the key support including a channel having first and second ends, a retaining key having opposing first and second ends and supported by the key support, the retaining key extending through the channel with the first and second ends thereof respectively projecting from the first and second ends of the channel, where the retaining key is configured for movement along a longitudinal axis between locked and released configurations, where in the locked configuration the retaining key retains a portion of the product when the product is supported by the container body and in the released configuration the retaining key is retracted to facilitate removal of the product from the container body when the product is supported thereby, and a key latch disposed proximate the second end of the retaining key and movable between installation and operational configurations, the key latch including a retaining ear configured to extend generally transverse to the longitudinal axis of the retaining key and beyond a width of the channel when the key latch is in the operational configuration such that the retaining ear restricts movement of the retaining key through the channel beyond the locked configuration, and when the key latch is in the installation configuration, the retaining ear allows insertion of the second end of the retaining key into the first end of the channel and out of the second end of the channel.

[0015] Moreover, in some embodiments, the key latch is coupled to the retaining key through a hinge. In some embodiments, the hinge is a living hinge and the key latch is integrally formed with the retaining key. In addition, in some embodiments, the retaining ear is a first retaining ear and the key latch includes a second retaining ear extending in an opposite direction from the first retaining ear. In some embodiments, the key latch is lockable in the operational configuration. Moreover, in some embodiments, the key latch includes a tab and the retaining key includes a catch that is operable to engage the tab to lock the key latch in the operational configuration. Also, in some embodiments, the key latch is a first key latch and the retaining ear is a first retaining ear and the retaining key further includes a second key latch disposed proximate the first end of the retaining key and movable between installation and operational configurations.

[0016] In some embodiments, the key support is a first key support and the channel is a first channel, the container body includes a second key support including a second channel, and the second key latch includes a second retaining ear configured to extend generally transverse to the longitudinal axis of the retaining key and beyond a width of the second channel when the key latch is in the operational configuration such that the second retaining ear restricts movement of the retaining key through the second channel beyond the locked configuration.

[0017] Consistent with another aspect of the invention, a package for a product may include a container body configured to support the product and including a recess through which the product may be removed from the container body, the container body further including first and second key supports disposed on opposite sides of the recess, and first and second retaining keys respectfully supported by the first and second key supports of the container body, the first retaining key movable along a first axis, where the first retaining key includes a first catch member that, when the first retaining key is moved along the first axis in a first direction towards the second retaining key, engages a second catch member disposed on the second retaining key to restrict movement of the first retaining key in a second, opposite direction along the first axis.

[0018] In addition, in some embodiments, the second retaining key is movable along a second axis that is substantially coincident with or substantially parallel with the first axis. Also, in some embodiments, the first and second catch members face one another. Moreover, in some embodiments, the first and second catch members each include a plurality of teeth. Further, in some embodiments, the plurality of teeth includes a plurality of saw teeth. Also, in some embodiments, the plurality of teeth includes a plurality of rounded teeth. Further, in some embodiments, the first and second retaining keys are substantially identical to one another.

[0019] Other implementations may include a key retention system, a retaining key, a mold for a retaining key and / or a portion of a container body, and various methods for making and / or using any of the aforementioned constructions.

[0020] These and other advantages and features, which characterize the invention, are set forth in the claims annexed hereto and forming a further part hereof. However, for a better understanding of the invention, and of the advantages and objectives attained through its use, reference should be made to the Drawings, and to the accompanying descriptive matter, in which there is described example implementations of the invention. This summary is merely provided to introduce a selection of concepts that are further described below in the detailed description, and is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.BRIEF DESCRIPTION OF THE DRAWINGS

[0021] FIG. 1 is a top perspective view of one implementation of a product package including a key retention system, including a retaining key in a locked configuration that retains a product in the package.

[0022] FIG. 2 is a top plan view of the product package of FIG. 1.

[0023] FIG. 3 is a top perspective view of a retaining key in the product package of FIG. 1.

[0024] FIG. 4 is a top perspective view of the retaining key of FIG. 3, with the first portion rotated relative to the second portion through the range limited hinge and the key latch disengaged.

[0025] FIG. 5 is a side elevational view of the retaining key of FIG. 3, with rotation of the first portion relative to the second portion illustrated in phantom.

[0026] FIG. 6 is a top plan view of the retaining key of FIG. 3.

[0027] FIG. 7 is a cross-sectional view of the retaining key of FIG. 3, taken along lines 7-7 of FIG. 6.

[0028] FIGS. 8 and 9 are enlarged perspective views of the key supports in the product package of FIG. 1.

[0029] FIG. 10 is a top perspective view of the product package of FIG. 1, with the retaining key in a released configuration.

[0030] FIG. 11 is a top perspective view of the product package of FIG. 1, illustrating installation of the retaining key.

[0031] FIG. 12 is a top perspective view of another implementation of a retaining key incorporating a key latch.

[0032] FIG. 13 is a cross-sectional view of the product package of FIG. 1, taken through lines 13-13 of FIG. 2.

[0033] FIG. 14 is an enlarged cross-sectional view of a portion of a product package including a key retention system incorporating a recess to retain a retaining key in a locked configuration.

[0034] FIG. 15 is an enlarged cross-sectional view of a portion of a product package including a key retention system incorporating a ledge to retain a retaining key in a locked configuration.

[0035] FIG. 16 is an enlarged cross-sectional view of a portion of a product package including a key retention system incorporating a retainer to retain a retaining key in a locked configuration.

[0036] FIG. 17 is an enlarged cross-sectional view of a portion of a product package including a key retention system incorporating a retaining key to retain another retaining key in a locked configuration.

[0037] FIG. 18 is a top perspective view of another implementation of a product package including a key retention system, including a pair of toothed retaining keys in a disengaged configuration.

[0038] FIG. 19 is a perspective view of one of the toothed retaining keys illustrated in FIG. 18.

[0039] FIG. 20 is a perspective view of the product package of FIG. 18, with the pair of toothed retaining keys in a locked configuration.

[0040] FIG. 21 is a perspective view of another implementation of a toothed retaining key that may be used in the product package of FIG. 18.

[0041] FIG. 22 is a perspective view illustrating engagement of two of the toothed retaining keys of FIG. 21.

[0042] FIG. 23 is a top perspective view of another implementation of a product package including a key retention system, including a retaining key with a pair of key latches and in a disengaged configuration.

[0043] FIG. 24 is a perspective view of the retaining key illustrated in FIG. 23.

[0044] FIG. 25 is a perspective view of the product package of FIG. 23, with the retaining key in a locked configuration.DETAILED DESCRIPTION

[0045] FIGS. 1 and 2 illustrate an implementation of a product package 10 including a container body 12 including one or more recesses 14 for housing a product 16, as well as a key retention system 18 for use in containing product 16 within, and releasing product 16 from, container body 12. Key retention system 18 in the illustrated implementation is a hinged key retention system that includes a hinged retaining key 20 that spans recess 14 and is supported at opposite ends by a pair of key supports 22, 24, and that additionally includes a key latch 26 configured to retain the hinged retaining key 20 in key support 24. In the illustrated implementation, hinged retaining key 20 is plastic and formed via injection molding, although other materials (e.g., metal), combinations of materials, and / or manufacturing techniques, e.g., thermoforming, 3D printing, casting, machining, etc., may be used in other implementations.

[0046] In some implementations, the product to be contained may be a medical device, instrument, or component. In other implementations, the product to be contained may be a consumer product, such as a children's toy, a household good, tool, or the like. However, this is not to be understood to be limiting, as the retaining key and key support may be used as part of a package for an innumerable variety of products, components, devices, or the like. Container body 12 may support product 16 in two dimensions X, Y in order to minimize movement of the product in the container body. Further, container body 12 may support product 16 in one direction of a third dimension Z (referred to herein as an insertion direction), only leaving one direction of the third dimension Z unsupported by container body 12 (i.e., the opening of container body 12). Dimensions X, Y, and Z do not imply any particular physical orientation, and are provided for illustrative purposes only. Retaining key 20, when in a locked configuration as illustrated in FIG. 1, restricts movement of product 16 in the opposite direction along the third dimension Z (referred to herein as a removal direction), and thereby retains product 16 in container body 12.

[0047] In some implementations, container body 12 is constructed of plastic, e.g., as may be formed via thermoforming, injection molding, blow molding, or rotational molding (among others). In other implementations, container body 12 may be constructed of metal, paper, or any other suitable material or combination of materials as is generally known in the art. Although any suitable method may be used in forming container body 12 and each key support 22, 24, it may be desirable in some implementations for container body 12 and each key support 22, 24 to be integrally-formed with container body 12 via a molding process. In some implementations, this molding may be achieved through an injection molding process; in other implementations, the molding may be achieved through a thermoforming process. In such implementations, each key support 22, 24 may be molded or formed as an integral part of container body 12 from a mold during the molding or forming of container body 12 itself. In other implementations, each key support 22, 24 may be separately constructed, but either permanently or removably affixed to container body 12. In addition, container body 12 may additionally have formed therein various structures, e.g., various instructional icons, text, and / or recesses capable of providing information such as instructions on how to release a product, what product is stored in the product package, etc.

[0048] In addition, while a single key retention system 18 including a retaining key 20 and pair of key supports 22, 24 is illustrated in FIGS. 1-2, it will be appreciated that container body 12 may support multiple products in different recesses, and that any product supported in container body 12 may be retained in container body 12 by more than one key retention system, such that any number of key retention systems may be utilized in different product packages. Furthermore, various types of key retention systems may be used in different product packages, including key retention systems that do not completely span a recess, but that instead are cantilevered over at least a portion of the recess, such as is the case with the various types of key retention systems disclosed in U.S. Pat. No. 10,577,165 to Sadowski et al. and U.S. application Ser. No. 18 / 420,665 filed by Erickson et al. on Jan. 23, 2024, both of which are assigned to the same assignee as the present application, and both of which are incorporated by reference herein.

[0049] It will be appreciated that product package 10 is merely one of an innumerable number of package designs that may be utilized, as the configuration of container body 12 and the recesses defined therein, the number and types of key retention systems, etc., may vary considerably based upon the type of product to be housed in the product package. Therefore, the invention is not limited to the specific configuration illustrated in FIGS. 1-2.

[0050] With additional reference to FIGS. 3-7, an example implementation of key retention system 18 is illustrated in greater detail. As illustrated in FIGS. 3-7, key retention system 18 includes a retaining key 20 that incorporates both a key latch 26 and a range limited hinge 28, the use and configuration of which will be discussed in greater detail below. It will be appreciated, however, that in other implementations, a retaining key may include only one of a range limited hinge and a key latch, and further, that a key latch may be used in connection with other types of retaining keys, e.g., cantilevered retaining keys in some implementations. Retaining key 100 of FIG. 12 (discussed in greater detail below) is an example of a retaining key that incorporates a key latch but no range limited hinge. Furthermore, in some implementations, retaining key 20 may omit key latch 26, such that retaining ears 54, 56 thereof are disposed in a fixed position on the retaining key, Therefore, the invention does not require a retaining key to include both a key latch and a range limited hinge, and each of these features may be used independently from one another in other implementations.

[0051] As illustrated in FIGS. 1-2, key retention system 18 utilizes a pair of key supports 22, 24 that are disposed on opposite sides of recess 14, and which are configured to respectively receive first and second portions 30, 32 of retaining key 20. First and second portions 30, 32 are joined together by a range limited hinge 28 that in the illustrated implementation is a living hinge that is integrally molded with first and second portions 30, 32, although in other implementations hinge 28 may be formed using other constructions that may be fastened or otherwise coupled to first and second portions 30, 32. Hinge 28 is range limited insofar as relative rotation between first and second portions 30 is constrained to a predetermined range, which results in retaining key 20 being substantially rigid in the removal direction along axis Z when portions 30, 32 are received in key supports 22, 24.

[0052] As illustrated in FIGS. 3-7, retaining key 20 generally includes an outwardly-facing or top surface 34, an inwardly-facing or bottom surface 36, side surfaces 38, 40, and first and second ends 42, 44. Outwardly-facing surface 34 generally faces away from recess 14 of container 12 when retaining key 20 is installed on package 10, and inwardly-facing surface 36 faces towards recess 14, although it should be appreciated that references to “outwardly-facing,”“inwardly-facing,”“top,” and “bottom” are used only to simplify the discussion hereinafter, and that surfaces 34, 36 may be oriented in different directions in other implementations. Further, for the purposes of the discussion hereinafter, and as illustrated in FIG. 3, retaining key 20 may be considered to include a length or longitudinal axis L along which retaining key 20 moves between locked and released configurations, a width axis W that is transverse to axis L, and a thickness axis T that is transverse to both of axes L and W, and along which surfaces 34, 36 are generally separated, although it will be appreciated that the nomenclature used for these axes should not be considered as not limiting, as a retaining key in other implementations may have varying dimensions and geometries.

[0053] In the illustrated implementation, hinge 28 is generally configured to rotate about an axis that is substantially parallel to and / or coaxial with the width axis W, and range limitation is provided by a pair of opposing stop members 46, 48 on portions 30, 32, which are configured to abut one another when retaining key 20 is in a locked configuration and portions 30, 32 are received in key supports 22, 24, to restrict relative rotation between second portions 30, 32. In some implementations, hinge 28 and stop members 46, 48 are separated from one another generally along the thickness axis T, with hinge 28 closer to outwardly-facing surface 34 than inwardly-facing surface 36, and stop members 46, 48 closer to inwardly-facing surface 36 than outwardly-facing surface 34, such that relative rotation between first and second portions 30, 32 is only permitted from the configuration illustrated in FIG. 5 in direction R. It should be appreciated that while the range limited configuration illustrated in FIG. 5 provides a substantially planar outwardly-facing and inwardly-facing surfaces 34, 36 across both portions 30, 32, in other implementations, the outwardly-facing and / or inwardly-facing surfaces in the range limited configuration need not be planar, and could be, for example, concave or convex to accommodate different heights of products relative to the recess in the container.

[0054] In some implementations, first portion 30 and / or second portion 32 may also include one or more retaining ears, e.g., retaining ears 50, 52, which may be positioned along a side of retaining key 20, and which may function to maintain retaining key 20 in a locked configuration once installed in key supports 22, 24. Further, one or more additional retaining ears, e.g., retaining ears 54, 56, may be disposed proximate end 44 of retaining key 20 to restrict removal of retaining key 20 from key support 24. In addition, one or more closed relief slots (e.g., closed relief slots 58, 60) may be disposed adjacent one or more of retaining ears 50, 52, 54, 56 to allow for flexure of such retaining ear(s) and thereby better accommodate manufacturing and other variations in key support 22 and / or key support 24, as described in the aforementioned '665 application.

[0055] With reference to FIGS. 8-9, key support 22 may be configured with a tab void 62, and key support 24 may be configured with a release void 64 and a tab void 66. Release void 64 of key support 24 (FIG. 9) may be configured to receive at least a portion of second portion 32 of retaining key 20 when retaining key 20 is in a released configuration (see FIGS. 9 and 10). Tab voids 62, 66 may also be configured to receive at least a portion of first and second portions 30, 32 of retaining key 20. Each tab void 62, 66 may further comprise a channel 68, 70 defined by a pair of tapered walls 72, 74 and 76, 78 on each side of channel 68, 70 for receiving first and second portions 30, 32 of retaining key 20. In such implementations, tapered walls 72-78 are formed at an angle such that channels 68, 70 are narrower at the top of key supports 22, 24 and wider at the bottom of key supports 22, 24. This difference in width of channels 68, 70 to the tapered walls 72-78 may allow first and second portions 30, 32 of retaining key 20 to be restricted from movement in directions other than generally along a longitudinal axis L of retaining key 20 by tab voids 62, 66 of key supports 22, 24. Each pair of tapered walls 72, 74 and 76, 78 is also separated by a gap 80, 82; however, in other implementations, tapered walls 72-78 may join together such that gaps 80, 82 are omitted and channels 68, 70 are open only on opposing ends, e.g., where retaining key 20 is sized and configured to enable first and second portions 30, 32 to be inserted into one end of channels 68, 70 when loading retaining key 20 in key supports 22, 24.

[0056] In the locked configuration (FIGS. 1 and 2), retaining key 20 is positioned such that first portion 30 is positioned within channel 68 and second portion 32 is positioned within channel 70, and with retaining ears 50, 52 disposed at one end 84 of channel 70 and with retaining ears 54, 56 disposed at an opposite end 86 of channel 70. The ears 50-56 are sized and configured relative to walls 76, 78 that define channel 70 (e.g., they project outwardly from second portion 32 in a direction generally transverse to longitudinal axis L beyond the space provided between walls 76, 78) to restrict movement of second portion 32 along longitudinal axis L. Further, ears 54, 56 are separated from ears 50, 52 along longitudinal axis L such that all ears 50-56 are desirably external to channel 70 when in the locked configuration. In addition, in the illustrated implementation of the locked configuration, first portion 30 of retaining key 20 spans across recess 14 and is retained within channel 68 of key support 22 so that the product is retained in the container.

[0057] In order to release product 16 from package 10, movement is induced between the locked and released configurations by engaging the top of second portion 32 of retaining key 20 with a finger or instrument and sliding second portion 32 towards the released configuration. FIG. 10 illustrates retaining key 20 after being moved from the locked configuration to the released configuration, whereby second portion 32 is retracted away from product 16 contained within container body 12, thereby disengaging first portion 30 from channel 68 of key support 22 and allowing for rotation of first portion 30 about range limited hinge 28 to a position such as illustrated in FIG. 10, which allows for removal of product 16 (not shown in FIG. 10). It will also be noted that product 16 may also be removed without the need for retaining key 20 to be completely removed from container 12. It should also be noted that hinge 28 in some implementations may be positioned on retaining key 20 at a location such that when retaining key 20 is in the released configuration, the hinge is located adjacent to key support 24 to minimize the degree to which the retaining key obstructs the opening to recess 14 during removal of product 16 from recess 14.

[0058] In addition, when retaining key 20 is moved from the locked configuration to the released configuration, retaining ears 50, 52 of second portion 32 move from end 84 to end 86 of channel 70, such that movement of second portion 32 back to the locked configuration is restricted by channel 70. In other implementations, however, movement of retaining ears 50, 52 all of the way to end 86 may not be supported, e.g., such that retaining ears 50, 52 are disposed within channel 70 when retaining key 20 is in the released configuration.

[0059] It will therefore be appreciated that, when retaining key 20 moves between the locked and released configurations, retaining ears 50, 52 move through channel 70. In addition, relief slots 58, 60 allow retaining ears 50, 52 to deflect inwardly and compress relief slots 58, 60 when disposed within channel 70. In addition, the amount of deflection may vary based upon the separation between walls 76, 78, thereby providing more consistent frictional resistance over a wider range of wall 76, 78 separations.

[0060] The spanning nature of key retention system 18 provides a number of benefits over convention designs. For example, in some implementations, material costs and thicknesses may be reduced while still providing sufficient containment of heavier products. Some conventional approaches, for example, require a 50-60 mil thickness container, as well as an inner tray or retainer, in order to sufficiently contain a 3 lb. product. In contrast the herein-described techniques may be capable of sufficiently containing a similar product using 35 mil or thinner packaging, and without the need for an additional inner tray or retainer. Relatively smaller containers, using fewer retainers, may also be used to contain products using the herein-described techniques. Furthermore, the need for multiple types of materials, and multiple containers and / or trays may be reduced or eliminated. Some conventional approaches, for example, require the use of multiple trays manufactured from rigid polyester type materials in order to provide sufficient containment. In contrast, with the herein-described techniques, all components in a product package may be formed of less rigid materials such as HDPE, and without the need for an inner tray to protect against outer tray abrasion. In addition, in some implementations, assembly and disassembly is relatively quicker and easier than conventional designs. Other benefits will be appreciated by one of ordinary skill in the art having the benefit of the instant disclosure.

[0061] Installation of retaining key 20 into container 12 in some implementations may be performed by inserting first end 42 of retaining key 20 into end 86 of channel 70 of key support 24 until second portion 32 is positioned as illustrated in FIG. 10, with retaining key 20 substantially in the released configuration. In other implementations, however, a key latch 26 may be used to enable retaining key 20 to be installed into container 12 by inserting second end 44 of retaining key 20 into end 84 of channel 70 of key support 24, as illustrated in FIG. 11.

[0062] As illustrated in FIGS. 3-7, key latch 26 is disposed proximate end 44 of retaining key 20 and is movable between an installation configuration (as illustrated in FIG. 4) and an operational (as illustrated in FIGS. 3 and 5-7) configuration. The key latch includes one or more retaining ears (e.g., retaining ears 54, 56) that extend generally transverse to the longitudinal axis of retaining key 20, and beyond a width of channel 70 when key latch 26 is in the operational configuration, such that retaining ears 54, 56 restrict movement of the retaining key through the channel beyond the locked configuration (see, e.g., FIG. 2).

[0063] Key latch 26 also includes narrowed body 88 that is coupled to second portion 32 through a living hinge 90 proximate outwardly-facing or top surface 34, which allows for movement of key latch 26 between the installation and operational configurations.

[0064] The width of narrowed body 88 and living hinge 90 are such that key latch 26 may pass through gap 82 of channel 70 of key support 24. As such, when key latch 26 is in the installation configuration as illustrated in FIG. 4, retaining ears 54, 56 are positioned away from key support 24, allowing for second end 44 of retaining key 20 to be inserted into end 84 of channel 70 and out of end 86 of channel 70, as illustrated in FIG. 10.

[0065] Further, as illustrated in FIGS. 4 and 7, key latch 26 additionally includes a tab 92 that is configured to engage a catch 94 formed on inward-facing or bottom surface 36 of second portion 30 to snap key latch 26 into the operational configuration after retaining key 20 has been installed into key support 24. By doing so, retaining ears 54, 56 of retaining key 20 thereafter restrict removal of retaining key 20 from key support 24.

[0066] It will be appreciated that other manners of maintaining key latch 26 in the operational configuration may be used in other implementations, e.g., other snap or press-fit couplings, one or more fasteners, etc. In addition, other manners of coupling key latch 26 to second portion 32 may be used in other implementations, e.g., other hinge designs. In still other implementations, key latch 26 may be a physically separate component from second portion 32 and may be installable onto second portion 32 after second portion 32 is installed into key support 24. As such, when in the installation configuration, the key latch is physically separated from second portion 32.

[0067] Various benefits may be obtained through the use of a key latch as described herein. For example, the key latch enables a retaining key to be installed into a key support within minimal force and / or from end 84 of key support 24 rather than end 86 (as may be the case in implementations where no key latch 26 is used), and in some instances, may enable a reduction in size of the key support (particularly of the recess into which the retaining key projects when in the released configuration), and thus of the overall container. Doing so also facilitates automated insertion of a retaining key in some implementations. Locking of the key latch into the operational configuration effectively restricts removal of the retaining key from the key support, although it will be appreciated that in some implementations, a key latch may be unlockable (potentially using a dedicated tool) to allow for removal of the retaining key.

[0068] It will be appreciated that a key latch may also be used with other retaining key designs, e.g., a retaining key supported by a single key support and configured to cantilever over a recess rather than fully spanning the recess. FIG. 12, for example, illustrates a retaining key 100 includes first and second ends 102, 104, a retaining ear 106 with a closed relief slot 108, and a key latch 110 joined proximate second end 104 using a living hinge 112. Key latch 110 includes a pair of retaining ears 114, 116 and a tab 118 that engages a catch 120 on retaining key 100 to lock key latch 110 into an operative configuration. Retaining key 100 is otherwise similar to various retaining keys discussed in the aforementioned '665 application, but is installable into a key support with reduced effort by inserting the retaining key into the key support in a similar manner to that described above in connection with FIG. 11.

[0069] The herein-described implementations may provide various benefits over conventional designs. For example, a hinged retaining key as described herein may be able to span a container recess and be secured to key supports on both sides of the container recess to retain a product in the recess, yet when moved from a locked configuration to a released configuration will hinge to allow the product to be removed from the container without impediment, and without the need to remove the hinged retaining key from the container. In addition, the incorporation of stop members maximizes holding force when in the locked configuration by preventing relative rotation of the different portions of the hinged retaining key. In addition, in some implementations, the hinged retaining key dimensions and hinge placement may be such that the hinged retaining key may be inserted into the container without the need for excessive space in the container, and in some instances, without the need for a key latch. Furthermore, in some implementations, the hinged retaining key becomes integral to the container, and requires the use of a tool or other mechanism in order to be removed. In addition, in some implementations incorporating a key latch, a retaining key may be inserted into a container without interference, and then when the key latch is closed and latched, the retaining key cannot be removed from the container without the use of a tool or other removal mechanism.

[0070] It will be appreciated that the various retaining keys, key supports, and containers may be formed in various manners, e.g., as integral components formed via blow molding or injection molding, and that some implementations may include molds suitable for forming such components, as well as methods of manufacturing and / or using such components.

[0071] Next, with reference to FIGS. 13-17, it will be appreciated that different types of key supports may be used in other implementations to restrict relative rotation between the first and second portions of a hinged retaining key. In particular, key support 22 may be considered to be a channel-type key support as it is configured with a channel 68 for receiving first portion 30 of hinged retaining key 20 to restrict relative rotation between first and second portions 30, 32 of hinged retaining key 20, as illustrated in FIG. 13. Key support 22 is configured similarly to key support 24, and in some implementations, may have similar dimensions to support the insertion of other types of retaining keys.

[0072] However, other key support configurations may be used to restrict the relative rotation in other implementations. As illustrated in FIG. 14, for example, a container body 130 may include a key support 132 configured as a receptacle (e.g., a slot, a hole, or some other receptacle) formed therein for receiving first portion 30 of hinged retaining key 20 to restrict relative rotation of first portion 30 and thereby retain hinged retaining key 20 over a recess 134. Similarly, as illustrated in FIG. 15, a container body 140 may include a key support 142 configured as a ledge formed therein for overlapping first portion 30 of hinged retaining key 20 to restrict relative rotation of first portion 30 and thereby retain hinged retaining key 20 over a recess 144.

[0073] As illustrated in FIG. 16, as another example, a container body 150 may include a key support 152 including a receiver 154 for receiving a post 156 of a retainer 158 that extends over a recess 160 to restrict relative rotation of first portion 30 of hinged retaining key 20. It will be appreciated that receiver 154 and post 156 may each be configured to engage one another to secure retainer 158 in place. To this extent, in some implementations receiver 154 and / or post 156 may be configured for friction fit with one another, or one or both of receiver 154 and / or post 156 may include cooperative tabs, catches, resilient members, etc. to restrict removal of post 156 from receiver 154 after insertion.

[0074] FIG. 17 illustrates yet another container body 170 including a key support 172 that is a channel-type key support, but that is disposed at an elevation such that a retaining key 174, which in some implementations may be similar in configuration to retaining key 100 of FIG. 12, may be supported within a channel 176 of key support 172 and extend over a recess 178 to restrict relative rotation of first portion 30 of hinged retaining key 20 and thereby retain hinged retaining key 20 over recess 178.

[0075] FIGS. 18-20 next illustrate another implementation of a product package 200 including a container body 202 including one or more recesses 204 for housing a product (not shown), as well as a key retention system 206 for use in containing a product within, and releasing the product from, container body 202. Key retention system 206 in the illustrated implementation includes a pair of retaining keys 208, 210 that project over recess 204 and that are respectively supported by a pair of key supports 212, 214. In the illustrated implementation, each retaining key 208, 210 is plastic and formed via injection molding, although other materials (e.g., metal), combinations of materials, and / or manufacturing techniques, e.g., thermoforming, 3D printing, casting, machining, etc., may be used in other implementations. Each key support 212, 214 may, in some implementations, be configured in a similar manner to key supports 22, 24 as described above in connection with FIGS. 8-9.

[0076] As illustrated in FIG. 19, retaining key 210 may include a catch member 216 as well as one or more retaining ears (e.g., retaining ears 218, 220), and may be movable along an axis 222. While retaining key 208 may differ from retaining key 210 in some implementations, in the illustrated implementation retaining key 208 is substantially identical to retaining key 210, and includes a similar catch member 224. Furthermore, retaining key 208 is movable along an axis that is substantially coincident or substantially parallel with axis 222 along which retaining key 210 is movable.

[0077] In use, each of retaining keys 208, 210 is inserted in its respective key support 212, 214, which results in catch members 216, 224 facing one another and extending towards one another across recess 204 as illustrated in FIG. 18. Moving one or both of retaining keys 208, 210 along their respective axes and towards one another results in the locked configuration illustrated in FIG. 20, with catch members 216, 224 engaging with one another and restricting movement of each retaining key 208, 210 in opposite directions (i.e., away from one another).

[0078] As illustrated in FIG. 19, catch members 216, 224 include a plurality of teeth, which in the illustrated embodiment are saw teeth that are configured with a profile that allows for the catch members to ride along one another as retaining keys 208, 210 are moved toward one another, but that restricts movement of retaining keys 208, 210 away from one another once catch members 216, 224 are engaged. It will be appreciated that a wide variety of other catch member configurations may be used, and that in some implementations, catch members may be configured to either prevent bidirectional movement or facilitate bidirectional movement, depending upon whether it is desirable to allow for retaining keys 208, 210 to be disengaged from one another. In some implementations, for example, it may be desirable to restrict disengagement of retaining keys 208, 210, e.g., where the product can simply be slid under the retaining keys after other key retention systems are disengaged. In other implementations, however, it may be desirable for catch members 216, 224 to engage with one another, but still allow for separation of the retaining keys from one another when it is desirable to remove a product from the packaging.

[0079] FIGS. 21-22, for example, illustrate a pair of toothed retaining keys 230, 232 configured to be supported in key supports 212, 214 of product package 200 of FIG. 18. As illustrated in FIG. 21, retaining key 230 includes a catch member 234 and a pair of retaining ears 236, 238, and is movable along an axis 240. As illustrated in FIG. 22, which illustrates retaining keys 230, 232 in a locked configuration, retaining key 232 may be substantially identical to retaining key 230, and may include a catch member 242 that mates with catch member 234. Catch members 234, 242 each include a plurality of rounded teeth, and it will be appreciated that an innumerable number of different types of catch members may be used in different implementations, including one or more teeth, recesses, protrusions, tabs, etc. capable of engaging another retaining key when a retaining key is moved along its axis toward the other retaining key. Further the catch members 234, 242 need not be identical in other implementations, and as noted above, may be configured to either allow or restrict separation of the catch members after the retaining keys 230, 232 are engaged in a locked configuration.

[0080] FIGS. 23-25 next illustrate another implementation of a product package 250 including a key retention system 252 that includes a retaining key 254 with a pair of key latches 256, 258. As illustrated in FIG. 24, each key latch 256, 258 is disposed at an opposite end of retaining key 254, and may be configured similar to key latches 26 and 110 discussed above. Retaining key 254 is sized and configured to span a recess 260 in a container body 262 and be received in a pair of key supports 264, 266 disposed on opposite sides of the recess. As illustrated in FIG. 23, retaining key 254 may be inserted into each key support 264, 266 while key latches 256, 258 are in the installation configurations illustrated in FIGS. 23 and 24, and then as illustrated in FIG. 25, each key latch 256, 258 may be pivoted downwardly and snapped into its operational configuration, thereby securing retaining key 254 across recess 260 and in each of key supports 264, 266. In some implementations, retaining key 254 may be hinged, while in other implementations, no hinge may be used. Moreover, in some implementations, key latches 256, 258 may be releasable when in the operational configuration (in some instances using a tool), while in other implementations, key latches 256, 258 may not be releasable.

[0081] It will be appreciated that, while certain features may be discussed herein in connection with certain implementations and / or in connection with certain figures, unless expressly stated to the contrary, such features generally may be incorporated into any of the implementations discussed and illustrated herein. Moreover, features that are disclosed as being combined in some implementations may generally be implemented separately in other implementations, and features that are disclosed as being implemented separately in some implementations may be combined in other implementations, so the fact that a particular feature is discussed in the context of one implementation but not another should not be construed as an admission that those two implementations are mutually exclusive of one another. Various additional modifications may be made to the illustrated implementations consistent with the invention. Therefore, the invention lies in the claims hereinafter appended.

Claims

1. A package for a product, comprising:a container body configured to support the product and including a recess through which the product may be removed from the container body, the container body further including first and second key supports disposed on opposite sides of the recess; anda retaining key supported by the container body and movable along an axis between locked and released configurations, the retaining key including first and second portions joined to one another by a range limited hinge for which relative rotation between the first and second portions is limited beyond a predetermined rotational relationship;wherein when in the locked configuration, the first and second portions are respectively supported by the first and second key supports with the retaining key spanning the recess and with the range limited hinge restricting relative rotation between the first and second portions of the retaining key to retain a portion of the product in the recess; andwherein when the retaining key is moved along the axis to the released configuration, the first portion of the retaining key is released from the first key support and is free to rotate relative to the second portion by the range limited hinge to allow for removal of the portion of the product retained by the retaining key from the recess.

2. The package of claim 1, wherein the second key support includes a channel having first and second ends, and the retaining key further comprises a key latch coupled to the second portion of the retaining key and movable between installation and operational configurations, the key latch including a retaining ear configured to extend generally transverse to the axis of the retaining key and beyond a width of the channel when the key latch is in the operational configuration such that the retaining ear restricts movement of the retaining key through the channel beyond the locked configuration, and wherein when the key latch is in the installation configuration, the retaining ear allows insertion of the second portion of the retaining key into the first end of the channel and out of the second end of the channel.

3. The package of claim 1, wherein the hinge is a living hinge that is integral with the first and second portions.

4. The package of claim 1, wherein the retaining key further includes a retaining ear coupled to the second portion and extending generally transverse to the axis, the retaining ear configured to frictionally engage a first wall of the second key support within a channel of the second key support during at least a portion of the movement of the retaining key between the locked and released configurations.

5. The package of claim 4, wherein the retaining key further includes a closed relief slot formed in the retaining key adjacent to the retaining ear and configured to enable flexure of the retaining ear during movement of the retaining key between the locked and released configurations.

6. The package of claim 1, wherein the first and second key supports are integrally-formed with the container body.

7. The package of claim 6, wherein the container body and first and second key supports are formed of a thermoformed plastic.

8. The package of claim 1, wherein the first key support includes a channel configured to receive the first portion of the retaining key when the retaining key is in the locked configuration to restrict relative rotation between the first and second portions of the retaining key.

9. The package of claim 8, wherein the retaining key is a first retaining key and the first key support includes a second retaining key configured engage the first portion of the first retaining key when the first retaining key is in the locked configuration to restrict relative rotation between the first and second portions of the retaining key.

10. The package of claim 1, wherein the first key support includes a ledge and / or a receptacle configured to engage the first portion of the retaining key when the retaining key is in the locked configuration to restrict relative rotation between the first and second portions of the retaining key.11.-12. (canceled)13. A package for a product, comprising:a container body configured to support the product and including a key support, the key support including a channel having first and second ends;a retaining key having opposing first and second ends and supported by the key support, the retaining key extending through the channel with the first and second ends thereof respectively projecting from the first and second ends of the channel, wherein the retaining key is configured for movement along a longitudinal axis between locked and released configurations, wherein in the locked configuration the retaining key retains a portion of the product when the product is supported by the container body and in the released configuration the retaining key is retracted to facilitate removal of the product from the container body when the product is supported thereby; anda key latch disposed proximate the second end of the retaining key and movable between installation and operational configurations, the key latch including a retaining ear configured to extend generally transverse to the longitudinal axis of the retaining key and beyond a width of the channel when the key latch is in the operational configuration such that the retaining ear restricts movement of the retaining key through the channel beyond the locked configuration, and wherein when the key latch is in the installation configuration, the retaining ear allows insertion of the second end of the retaining key into the first end of the channel and out of the second end of the channel.

14. The package of claim 13, wherein the key latch is coupled to the retaining key through a hinge.

15. The package of claim 14, wherein the hinge is a living hinge and the key latch is integrally formed with the retaining key.

16. The package of claim 13, wherein the retaining ear is a first retaining ear and the key latch includes a second retaining ear extending in an opposite direction from the first retaining ear.

17. The package of claim 13, wherein the key latch is lockable in the operational configuration.

18. The package of claim 17, wherein the key latch includes a tab and the retaining key includes a catch that is operable to engage the tab to lock the key latch in the operational configuration.

19. The package of claim 13, wherein the key latch is a first key latch and the retaining ear is a first retaining ear and the retaining key further comprises a second key latch disposed proximate the first end of the retaining key and movable between installation and operational configurations.

20. The package of claim 19, wherein the key support is a first key support and the channel is a first channel, wherein the container body includes a second key support including a second channel, wherein the second key latch includes a second retaining ear configured to extend generally transverse to the longitudinal axis of the retaining key and beyond a width of the second channel when the key latch is in the operational configuration such that the second retaining ear restricts movement of the retaining key through the second channel beyond the locked configuration.

21. A package for a product, comprising:a container body configured to support the product and including a recess through which the product may be removed from the container body, the container body further including first and second key supports disposed on opposite sides of the recess; andfirst and second retaining keys respectfully supported by the first and second key supports of the container body, the first retaining key movable along a first axis, wherein the first retaining key includes a first catch member that, when the first retaining key is moved along the first axis in a first direction towards the second retaining key, engages a second catch member disposed on the second retaining key to restrict movement of the first retaining key in a second, opposite direction along the first axis.22.-27. (canceled)

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